Roof structure for railway cars



Sheet of 5 Feb. 25., 1969y D. F. voRos ROOF STRUCTURE FOR RAILWAY CARS Filed Maren 27, 19e? ATTORNEY n @I IV v .S R WAI i 1 w w m o /r W V 1.0. l F D AV.. we m- D |m -mi i l 1 C L L L GL r v f \|mr f a: fl l Qn: @s vm. WN .N\ v L||| 4l I nl f J 1 1 5. L 1 1 1 1 2 1 J( vmf L Q L L .L t

Feb. 25, 1969 D. F. voRos ROOF STRUCTURE FOR RAILWAY CARS Sheet Filed March 27, 1967 Feb. 25, 1969 D. F. VOROS Roor'- STRUCTURE FOR RAILWAY cARs Sheet Filed March 27, 1967 Feb. 25, 1969 o. F. voRosl 3,429,083

Roof STRUCTURE FOR RAILWAY cARs Filed March 27, 19e? sheet 4 of 5 1 c5 i E' Feb- 25, 1969 D. F. voRos ROOF STRUCTURE FOR RAILWAY CARS sheet. of 5' Filed March 27, 196'?l United States Patent O 3,429,083 ROOF STRUCTURE FOR RAILWAY CARS Donald F. Voros, St. Charles, Mo., assigner to ACF Industries, Incorporated, New York, N.Y., a corporation of New Jersey Filed Mar. 27, 1967, Ser. No. 626,102 U.S. Cl. 52-53 6 Claims Int. Cl. B61d 17/12; E04c 1/39; E04d I/30 ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION Conventional steel roofs are composed of multiple steel panels extending transversely of the car. The steel panels may be subassembled by butting the transverse anges, laying a steel seam cap over the abutting llanges, and then fastening the abutting flanges with a row of rivets. The subassembled roof structure is then applied to the box car superstructure. In the event of relatively small variations in dimensions, the metal roof structure may be stressed to conform to the intertting car structure. Prior U.S. Patents Nos. 1,450,243 and 1,461,721 show overlapping metal panels which are riveted together and are in nested relation only adjacent the eaves or upper sides of the box car.

DESCRIPTION OF INVENTION The roof structure of the present invention comprises a plurality of molded plastic panels to provide -a lightweight roof structure. As an example, a conventional steel roof for a fty (50) foot box car has a weight of around twenty-two hundred (2200) pounds while the roof structure of the present invention weighs only around eight hundred iifty (850 pounds). Such a weight reduction permits a greater capacity of lading in the box car. Adjacent lapping panels provide a generally uniform reinforcing box-shaped section extending transversely of the car for the full width of the car to reinforce the roof structure. The adjacent panels are adhesively bonded to each other at each side of the box-shaped section thereby providing a double seal against water leakage.

To receive the underlapping marginal portion of one of the adjacent panels, a recessed portion or indentation is provided on the underside of the overlapping panel adjacent the inner side of Va reinforcing channel-shaped rib for the full width of the car. As each panel is of a generally uniform thickness, a stepped or raised portion is provided on the outer surface of the overlapping panel adjacent the channel-shaped rib. The indentation permits a relatively smooth inner surface and a relatively tight fit at the side plate structures of the box car. In addition, the amount of lapping on each pair of panels may be varied to allow for a total car length variation as much as around seven (7) inches for a car of around fty (50i) feet in length without any change in panel design.

Another feature of this invention is in the manner of securing the roof structure. The plastic panels are not predrilled and upon positioning of the roof structure on 3,429,083 Patented Feb. 25, 1969 the box car, a template is attached at the side plate structure and holes are drilled in the plastic panels in alignment with the predrilled holes in the side plate structures thereby eliminating any necessity for prestressing the panels and reducing the possibilities of oversized holes and resulting water leakage.

The method of forming and securing the roof structure of the present invention comprises rst preassembling two roof halves, each half comprising one metal end panel and a plurality of plastic panels, positioning a center key panel on the car, and then positioning the -preassembled roof halves of the center panel. The center panel permits a car length adjustment of around two (2) inches for variations in car lengths.

The invention accordingly comprises the constructions hereinafter described, the scope of the invention being indicated in the following claims.

In the accompanying drawings, in which one of various possible embodiments of the invention is illustrated,

FIGURES 1 and 1A form a composite plan of a box c-ar having a roof structure comprising the present invention;

FIGURE 2 is a partial side elevation of the box car and roof structure shown -in FIGURES 1 and 1A;

FIGURE 3 is a-n end elevation of the roof stucture on the box car;

FIGURE 4 is a section taken generally along line 4-4 0f FIGURE l;

FIGURE 5 is a section taken generally along line 5 5 of FIGURE l;

FIGURE 6` is a section taken generally along line 6-6 of FIGURE l;

FIGURE 6A is a section similar to FIGURE 6 but showing the adjustability of the lapping panels;

FIGURE 7 is a partial top plan of a plastic panel shown removed from the box car;

FIGURE 8 is a section taken generally along line 8-8 of FIGURE 7;

FIGURE 9 is a side elevation of the molded plastic roof panel shown in FIGURE 7;

FIGURE l0 is a plan showing a metal end panel and an adjacent plastic panel;

FIGURE l1 is a section taken generally along line 1 1-11 of FIGURE 10;

FIGURE l2 is an enlarged fragment of FIGURE 1 illustrating the center key panel with adjacent plastic panels mounted thereon, certain parts being broken away; and

FIGURE 13 is a section taken generally along line 13-13 of FIGURE l2.

`Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Referring now to the drawings for a better understanding of this invention, a railway box car is generally indicated 10 having sides 12 and ends 14-- As shown particularly in FIGURES 4 and 5, side 12 includes side posts 16 and side panels 18 secured thereto. A side plate 2l) extends longitudinally along each side 12 Iand has an outwardly extending upper flange 22 to support the roof structure generally indicated 24 and comprising the present invention.

Roof structure 24 comprises a center key panel 26 as shown particularly in FIGURES 12 and 13. Center panel 26 is positioned centrally of the length of box car 10 and secured to flanges 22 by suitable bolt and nut combinations. After positioning of center panel 26, a pair of roof subassemblies or roof halves generally indicated 28 are positioned between center panel 26 and ends 14 of railway car 10. Roof subassemblies 28 are secured to flanges 22 by suitable nut and bolt combinations 29 extending through aligned openings.

Each roof subassembly 2S comprises a metal end panel and a plurality of molded plastic panels 32. Each molded plastic panel 32 is generally identical and of a generally uniform thickness. Referring particularly to FIGURES 7, 8, and 9, each panel 32 has a channelshaped rib or reinforcement 34 extending transversely of the railway car 10. Rib 34 has tapered or sloping ends 35 and is of a uniform cross section between ends 35, A free lip or flange 36 extends outwardly from the outer side of rib 34. Formed adjacent the inner side of each rib 34 on the inner surface of panel 32 is an indentation or recessed portion 3S. Recessed portion 36 forms a stepped or outwardly extending projection 40 on the outer surface of panel 32. Main body portion 42 of panel 32 includes a plurality of relatively small projecting ribs 44 to reinforce body portion 42. A smooth marginal side portion 46 of body portion 42 adjacent ribs 44 is .adapted to be positioned beneath a rib 34 of an adjacent panel 32 and a smooth marginal end portion 48 is adapted to fit against upper flange 22 to provide a relatively tight fit therewith. To secure two molded plas tic panels 32 together and referring to FIGURES 6 and 6A, a suitable adhesive 47 such as a polyester or epoxy adhesive, is brushed onto the contacting surfaces of marginal side portion 46 of one panel and side portion 46 is then fitted within indentation 38 of an adjacent panel. The panels are suitably clamped together until the adhesive cures which may be twenty-four hours or more dependent on the particular adhesive employed and the ambient temperature. FIGURE 6A indicates the adjustment which may be made between overlapping panels 32 to vary the length of the roof structure by varying the amount of overlap between adjacent panels 32.

End metal panels 30 shown particularly in FIGURES l() and 1l include a downturned end fiange 49 which may be riveted to the adjacent box car end 14, The inner end of metal panel 30 is flared upwardly at 50 and outwardly at 52 to receive a marginal portion 46 of an adjacent plastic panel 32. Suitable mechanical fasteners, such as bolt and nut combinations 54, may be employed to secure the overlapping portion of metal panel 30 and adjacent plastic panel 32.

To assemble the roof structure comprising the present invention, the two roof halves or subassemblies 28 are each preformed from a plurality of molded plastic panels 32 and one metal end panel 30. Key panel 26 is then secured to side plates 20 centrally of the length of the car. Then, the two roof subassemblies 28 are placed over center panel 26 as shown particularly in FIGURES l2 and 13 and suitable openings are drilled in panels 32 in alignment with predrilled openings in flanges 22 of side plates 20. Bolt and nut combinations 29 secure subassemblies 28 to side plates 20. Nut and bolt combinations may be employed, if desired, to secure panels 32 to key panel 26 to avoid curing times normally required for adhesive securing means. In such event, a suitable sealing material could be placed between panels 26 and 32 to provide water tightness.

Molded plastic panel 32 may, for example, be formed of a reinforced fiber glass material. Other suitable thermoset or thermoplastic resins may be employed, such as polyesters, phenolics, epoxies, silicones, polyethylenes, and polypropylenes. Reinforced plastics usually include fibers of glass, asbestos, sisal or cotton in woven or nonwoven form. Glass fibers are most widely used with polyesters, phenolics and epoxy thermosets.

From the foregoing, it is understood that a lightweight roof:` structure for a railway box car is provided which may decrease the weight of a fifty foot box car around fourteen hundred pounds. The roof structure is formed from a plurality of molded plastic roof panels 32 which are arranged in an overlapping relation to provide a box-shaped reinforcement and a length variation of several inches, if desired, without changing the panel design. The panels 32 are secured to each other in a nested relation so as to provide a flush or smooth inner surface for fitting on side plates 20. Further, the panels have a double seal at the connecting box-shaped reinforcement to minimize any water leakage.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results obtained.

As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. In a railway box oar having a pair of side plate structures extending longitudinally thereof, a roof structure secured t0 the side plate structures and comprising, a plastic key panel secured between the side plate structures generally centrally of the length of the car, a plurality of connected molded plastic panels on each side of the key panel, each molded plastic panel having an upwardly projecting channel-shaped rib along a marginal portion thereof and a lip extending outwardly from the outer side of said rib, each of said molded plastic panels immediately adjacent said key panel having a rib fitting over and secured to the key panel, said rib extending transversely of the car and having an upwardly extending stepped portion adjacent the inner side thereof forming an indentation along the inner surface of the respective panel of a depth substantially equal to the thickness of the panel, the adjoining molded plastic panels being secured to each other with a marginal portion of one panel extending beneath the lip and rib of the adjacent panel and fitting within the indentation formed by the stepped portion of the adjacent panel, and means adhesively securing said adjoining molded plastic panels to each other along substantially the entire length of said lips and indentations thereby to provide watertight joints between adjacent panels.

2. In a railway box car as set forth in claim 1, each side plate structure including an upper outwardly extending fiange, said roof struct-ure extending over the flanges, and means securing the roof structure to the flanges.

3. In a railway box car having a pair of side plate structures extending longitudinally thereof, Ia roof structure secured to the side plate structures and comprising, a metal end panel at each end of the car secured to the side plate structures, a plurality of connected molded plastic panels between the metal end panels, each metal end panel being flared outwardly adjacent its inner end to receive in telescoping relation an adjacent molded plastic panel, means securing the metal end panels to the adjacent molded plastic panels, each molded plastic panel having van upwardly projecting channel-shaped rib along a marginal portion thereof and a lip extending outwardly from the outer side of said rib, said rib extending transversely of the car and having an upwardly extending stepped portion adjacent the inner side thereof forming an indentation along the inner surface of the respective panel of a depth substantially equal to the thickness of the panel, the adjoining molded plastic panels being secured to each other with a marginal portion of one panel extending beneath the lip and rib of the adjacent panel and fitting within the indentation formed by the stepped portion of the adjacent panel, and means adhesively securing said adjoining panels to each other along substantially the entire length of said lips and indentations thereby to provide watertight joints between adjacent panels.

4. In a railway box car having a pair of side plate structures extending longitudinally thereof, a key panel secured to the side plate structures generally centrally of the length of the car, a pair of preassembled roof halves extending between the key panel and the ends of the car, each roof half including a plurality of connected molded plastic panels, each plastic panel having an upwardly projecting -channel-shaped rib along one marginal side portion thereof and a relatively smooth opposed marginal side portion, said connected panels being secured to each other with an opposed marginal side portion of one panel extending beneath the rib of an adjacent panel to form a box-shaped reinforcing section therewith, means adhesively securing adjacent panels to each other along substantially the entire length of said box-shaped section and on both sides thereof to provide a watertight joint between adjacent panels, and means securing the roof halves to the side plate structures.

5. In a railway box car as set forth in claim 4, each roof half including a metal end panel ared outwardly adjacent its inner end and receiving in overlapping relation an adjacent plastic panel, and means securing the metal end panels to the adjacent plastic panels.

6. In a railway box car having a pair of side plate structures extending longitudinally thereof, a roof structure secured to the side plate structures and comprising, a metal end panel at each end of the car secured to the side plate structures, a plurality of connected molded plastic panels between the metal end panels, each metal end panel being flared outwardly adjacent its inner end to receive in telescoping relation an adjacent molded plastic panel, means securing the metal end panels to References Cited UNITED STATES PATENTS 1,450,243 4/ 1923 Bonsall 52-53 1,461,721 7/1923 Bonsall 52-53 1,655,699 1/1928 Houston 52--746 X 1,956,302 4/1934 Swanson 52-53 2,525,059 10/ 1950 Ashman 52-541 2,812,730 11/1957 Hermann 52--630 3,263,379 8/1966 Cisco 52-53 3,303,620 2/1967 Dawson et al. 52-309 OTHER REFERENCES Modern Plastics, February 1957, pp. 98, 99.

FRANK L. ABBOTT, Primary Examiner.

PRICE C. FAW, J R., Assistant Examiner.

U.S. Cl. X.R. 

